LOW FAT SPREAD WITH NON-PROTEINACEOUS CRYSTAL INHIBITORS

Abstract: The present invention regards a low fat spread comprising from about 30 to about 40 wt.% of a continuous fat phase and about 60 to about 70 wt.% of an aqueous phase. The fat phase further comprises a non-proteinaceous fat crystallisation inhibitor in an amount of less than 0.5 wt.% and a non-proteinaceous emulsifier. The aqueous phase contains a dairy protein in an amount of less than a bout 0.1 wt.%.

Description: LOW FAT SPRFAD WITH NON-PROTEINACEOUS CRYSTAL INHIBITORS Field of the Invention This invention pertains to protein containing spread products having less than or equal to 40% fat which exhibit long term storage stability based on a non- proteinaceous crystalline system without the need to stabilise the milk phase with thickeners or gelling agents. Background of the Invention Fat spreads such as butter and margarine having 40% and less fat, while desirable, have been observed to suffer from severe emulsion instability after prolonged storage at refrigerator temperature. Pools of oil and moisture were observed in such products. It is believed that the fat of the products re-crystallised upon storage causing the emulsion instability problem. It is known in the art that removing milk proteins from the aqueous phase of low fat spreads can address stability problems. However, removing the milk proteins from the compositions causes an unacceptable oral response and stable products in the presence of milk proteins require the presence of a thickening or a gelling agent in the aqueous phase. Suitable gelling agents such as gelatin, however, adversely effect taste and are rather more expense to process than margarines processed on so- called traditional processing lines as higher hygiene standards are required. It was thus observed that low fat spread products having long term stability for up to at least 5 weeks when stored at 5°C could be provided. Such products contain less than 0.5 wt. % of a non-proteinaceous fat recrystallisation inhibitor in combination with less than 0.1 wt.% milk protein, without the addition of a proteinaceous emulsifier. Summary of the Invention It is an object of the invention to provide a low fat spread having long term stability and comprising a oil- continuous emulsion, less than 0.1 wt.% milk protein, and less than 0.5 wt.% of a non-proteinaceous fat crystallisation inhibitor. It is another object of the invention to avoid the use of a gelling agent, such as gelatin, or thickener to provide a spread which is stable upon long term storage. Another object of the invention is to provide low fat spreads having good oral response, mouthfeel and melt without specialized and expensive processing equipment. Detailed Description of Preferred Embodiments Oil Phase The products of the invention have a smooth texture, rich mouthfeel and excellent long term stability. The term "long term stability" or "prolonged storage stability" means that the product does not exhibit destabilisation caused by fat recrystallisation or post crystallisation after storage at about 5°C for at least five weeks. Fat recrystallisation or post crystallisation destabilisation is evidenced by oil or moisture separating from the product. The fat of the composition will be present in amounts within the range of up to or equal to 40% based on the weight of the spread, preferably in a range of about 30 to 40%, most preferably 35 to 40% of the spread. Vegetable oils which may be included in the composition are the usual vegetable oils such as soybean oil, corn oil, cottonseed oil, peanut oil safflower oil, sunflower oil and rapeseed. The preferred fats are hydrogenated liquid and vegetable oils selected from the group of safflower oil, soybean oil, corn oil, rapeseed oil and mixtures thereof. Especially preferred is soybean oil. A non-proteinaceous fat crystallisation inhibitor is added to the composition in an amount of less than 0.5 wt.%, preferably 0.05 to 0.2 wt.%, most preferably 0.05 to about 0.1 wt.%. The inhibitors should have a hydrophilic/lipophilic balance (HLB) of 5 to 10, preferably 5 to 8. Suitable inhibitors include polyglycerol esters, sorbitan esters, and any other fat crystallisation inhibitors known in the art having the required HLB range and being food grade for use in spread products. The preferred inhibitor is polyglycerol ester and the most preferred polyglycerol esters are those containing fatty ester groups, preferably stearate esters. An example of a suitable fat crystallisation inhibitor is a polyglycerol ester known as Santone 3-1-SH having an HLB of 7 supplied by Van den Bergh of Lisle, 111 U.S.A.. Without being limited by theory, the fatty esters of the inhibitor agents interact with the oil ingredients of the oil phase to prevent post or re-crystallisation of fat during storage. Inhibitors having a low HLB of e.g. 2 or less provide stable products, however, change the melting point of the product to adversely effect its mouthfeel as the water-in-oil emulsifying effect becomes the primary effect of the inhibitor. Conversely, inhibitors having a high HLB, e.g.. greater than 10, effect the emulsion stability of the products. While the oil-in-water effect of these high HLB additions becomes too strong to maintain stable oil continuous emulsions. Products of the present invention not only exhibit stability upon prolonged storage but also exhibit excellent spreadability scores upon cycling temperatures of between 5°C and ambient temperatures (20°C back to 5°C) and furthermore show excellent spreadability scores at ambient temperatures after at least 5 weeks.. E ulsifiers used in the fat phase of the present spread include saturated and unsaturated monoglycerides, diglycerides, phosphatides and lecithin.. Preferably the emulsifiers are present in an amount of 0.1 to 0.4 wt.% of the composition. Preferably the emulsifier system comprises a mixture of saturated and unsaturated monoglycerides, preferably in a ratio of 1:1 unsaturated to saturated monoglycerides. Such a mix of the monoglycerides provide products having good long term stability. Aqueous Phase The present compositions must not contain more than 0.1 wt.% of a dairy protein, preferably about 0.005 to less than 0.1 wt.%, most preferably 0.005 to 0.02 wt.%. The amount of the dairy protein ingredient is critical to provide a good tasting, and excellent mouthfeel product. The dairy protein can be derived from any dairy source, such a whole milk, skim milk, cultured buttermilk, buttermilk powder, skim milk powder, yogurt, quark, frommage, whey powder, butter, etc. A preferred dairy source is whey powder. Non-dairy ingredients may also be present in the composition such as vegetable proteins e.g. soybean extracted proteins. The compositions of the invention may comprise a number of optional ingredients to provide desirable flavour and colour as known in the art. Flavours which are suitable include sodium chloride, butter flavours, fruit flavours, spices, nut flavours, vegetable flavours, herbs, dairy flavours, distilled beverage flavours, cheese flavours, seafood flavours, meat flavours, candy flavours, etc. as known in the art. Preferably the level of flavouring materials is less than 0.5 wt.%, more preferably 0.01 to 0.2 wt.%. Preferably the level of sodium chloride is from 0 to 4 wt.%, more preferred 0.1 to 3 wt.%, most preferred 0.5 to about 2 wt.%. Colours which are suitable include beta-carotene, annatto, turmeric, caramel colour, paprika and FD&C dyes. Typically the colours will be dissolved or dispersed in the fat phase or the water phase to expedite blending. Colours are present in the composition in an amount of less than 1 wt.%, preferably 0.001 to 0.1 wt.%. To control microbiological and oxidative deterioration, preservatives are incorporated in the composition to control mould and yeast growth, the products may contain benzoic acid, sorbic acid, phosphoric acid, lactic acid and the soluble salts of these and other materials. Preferred anti-microbials are potassium sorbate, sodium sorbate, potassium benzoate, sodium benzoate and phosphoric acid preferably incorporated at a level of up to 4 wt.%, more preferably 0.01 to 2 wt.%. Especially preferred is potassium sorbate. Acidifiers may be incorporated to maintain the pH of the aqueous phase of the product at a desirably level, preferably from 3 to 10, more preferably from 3.5 to 7. Suitable acidifiers are lactic acid and citric acid incorporated at a level of about 0.01 to 1 wt.%, preferably 0.01 to 0.1 wt.%. If desired, a chelating agent such a EDTA add salts so the light can be employed to tie up metal ions which may otherwise interact with one or more of the ingredients in an undesirable manner. Processing The compositions of the invention are processed generally by passing through a combination of a scraped surface heat exchangers (A-unit) and pin stirred crystallisers (C-unit) . The first process unit operator step preferably utilizes a scraped surface heat exchanger plus high speed phase invertor where the invertor is a crystalliser . In the preferred embodiment, the process sequence is A-A-C-A-C. Preferably, a plate heat exchanger (PHE) is utilized prior to the first cooling A step to provide process temperatures. Specifically, the oil phase is prepared by blending a liquid vegetable oil and selected emulsifiers with heat in a temperature range of from about 150 to 170°F (about 65° to 77°C) under agitation. The resulting mixture is then cooled to a range of about 110 to about 140°F (about 43° to about 60°C) and lecithin is then added, preferably with agitation to form the oil phase. The aqueous phase is prepared by heating water to about 150 to 170°F (about 65° to 77°C) and subsequently adding all dry ingredients except sodium chloride to the heated water. The resulting mixture is then cooled to a temperature range of about 110 to about 140°F (about 43° to about 60°C) . The salt is then added to the cooled mixture with agitation. Remaining water, dairy protein source and acidifying agent is then added to the mixture to form the aqueous phase. Premixing of the aqueous and oil phase is accomplished by adding the complete oil phase to the aqueous phase under continuous agitation. The phases are agitated to homogenise the aqueous and oil phases and optional ingredients such as flavours and colours may be added during the homogenisation agitation. The premix mixture passes from the homogeniser to a suitable heat exchanger where it is cooled. The following examples illustrate, without limitation, the present invention. Unless otherwise indicated, wt.% means the percentage of the ingredient based on the total composition. Example 1 The following 40% fat spread products were prepared: FORMULATIONS COMPOSITIONS A - E OIL PHASE A B C D E 78% liquid soybean 39.55 39.475 39.45 39.45 39.35 oil/22% soy oil hardened to 42°C Distilled saturated monoglycerides 0.175 0.325 0.225 0.175 0.175 Distilled unsaturated monoglycerides 0.175 0.225 0.175 0.175 Polyglycerol ester 0.1 0.2 Lecithin 0.1 0.2 0.1 0.1 0.1 AQUEOUS PHASE Whey powder 0.10 0.10 0.10 0.10 0.10 Lactic acid 0.07 0.07 0.07 0.07 0.07 Water 58.5 58.5 58.5 58.5 58.5 Potassium Sorbate 0.1 0.1 0.1 0.1 0.1 EDTA 0.007 0.007 0.007 0.007 0.007 Flavour 0.0125 0.0125 0.0125 0.0125 0.0125 Colour 0.0066 0.0066 0.0066 0.0066 0.0066 Total 100.0 100.0 100.0 100.0 100.0 Santone 3-1-SH supplied by Van den Bergh of Lisle, 111. having an HLB of 7. The EDTA and potassium sorbate were added to about 6% of the water and heated to a temperature of 175°F (79°C) to pasteurise the solution. The solution was then cooled to 140°F (60°C) and the sodium chloride was added for agitation for 10 minutes. The remainder of the water and the whey concentrate were added to the pasteurised salt containing solution. The lactic acid was added with agitation for 5 minutes to obtain a pH of 4.4. The oil phase was prepared by heating the soybean oil, the monoglycerides and polyglycerol ester to 170°F (77°C) . The heated oil solution was cooled to 140°F (60°C) and lecithin was added with mixing for 20 minutes. The complete oil phase, colour and flavour were premixed into the aqueous phase with agitation to form a homogenised composition. The homogenised composition was then passed through scraped surface heat exchangers and crystallisers and cooled to a temperature in a range of 40 to 50°F (4°-10°C) . The cooled composition was then filled into tubs and stored at 41°F (5°C) . The compositions were observed for spreadability and stability for at least 2 weeks at 5°C storage. It was observed that compositions A-C which did not contain the non-proteinaceous crystallisation inhibitor (polyglycerol ester) lost stability after 10 days at 5°C storage. Additionally, the compositions were observed to have poor spreadability (scores 2, 3 on a scale of 1-10) where 10 means excellent spread, no loose oil and water upon spreading and 1 means extreme emulsion destabilisation upon spreading resulting in loose water droplets. The inventive compositions D and E containing 0.1% and 0.2%, respectively, polyglycerol ester were observed to have excellent spreadability with scores of 9 and 10 which were maintained even after 10 days of storage at 5°C. Additionally, the compositions D and E have been observed to be stable at 5°C for about 6 months. Example 2 FORMULATIONS COMPOSITIONS F - I OIL PHASE F G H I 78% liquid soybean 39.45 39.45 39.45 39.45 oil/22% soy oil hardened to 42°C Distilled saturated monoglycerides 0.175 0.175 0.175 0.175 Distilled unsaturated monoglycerides 0.175 0.175 0.175 0.175 Polyglycerol ester 0.1 0.1 0.1 0.1 Lecithin 0.1 0.1 0.1 0.1 AQUEOUS PHASE Water 58.5 58.45 58.4 58.2 Salt 1.25 1.25 1.25 1.25 Whey powder 0.05 0.1 0.2 0.4 Lactic acid 0.07 0.07 0.7 0.07 Potassium sorbate 0.1 0.1 0.1 0.1 EDTA 0.007 0.007 0.007 0.007 Flavour 0.0125 0.0125 0.0125 0.0125 Colour 0.0066 0.0066 0.0066 0.0066 Total 100.0 100.0 100.0 100.0 Compositions F-I were prepared as describe in Example 1 except the amount of whey powder was varied from 0.05 to 0.4, respectively. It was observed that compositions F & G, containing 0.05% and 0.1% whey, respectively, had excellent spreadability scores of 10. Composition H containing 0.2 wt.% whey powder had a reduced spreadability score of 5. Composition I containing 0.4% whey powder had an low spreadability score of 3. It was thus observed that compositions containing more than about 0.2% whey powder had low spreadability and the total protein content level is critical.

Claims: AMENDED CLAIMS [received by the International Bureau on 22 July 1994 (22.07.94); original claims 1 and 5 amended; new claim 11 added; remaining claims unchanged (1 page)] I. An edible spread product comprising: (a) about 30 to about 40 wt.% of a fat phase, having 0.05 to 0.5 wt.% based on total composition of a non-proteinaceous fat crystallisation inhibitor having an HLB of from 5 to 10, and from 0,1 to 0,4 wt.% of a non-proteinaceous emulsifier system; and (b) 70 to 60 wt.% of an aqueous phase containing about 0,005 to less than about 0.1 wt.% of a dairy protein based on total composition. 5. A spread product according to claim 1, wherein the non- proteinaceous emulsifier is selected from the group of saturated monoglycerides, unsaturated monoglycerides, diglycerides and phosphatides and mixtures thereof. II. A spread product according to any one of the preceding claims wherein the dairy protein is derived from whey.

Inventors: CHIAVERINI MICHAEL, LEHOUILLER SCOTT ANTONIO, RECKWEG FREEK, CHIAVERINI, MICHAEL, LEHOUILLER, SCOTT, ANTONIO, RECKWEG, FREEK
Applicants: UNILEVER NV, UNILEVER PLC, UNILEVER N.V.
Application year: 1994
Main classification: A23D7
IPC codes: A23D7